Bulk containers



F. w. LOCKE BULK CONTAINERS Oct. 4, 1966 2 Sheets-Sheet 1 Filed Jan. 15, 1966 INVENTOR ATTORNEY E 0 Z W K U Q/MM, r M 3 G B 9 5 1 Z 1, p J @5 z ,5 6 5 5 5 ilk:

United States Patent 3,276,658 BULK CONTAINERS Frank W. Locke, 2021 Thomas Ave. S.,

Minneapolis, Minn. Filed Jan. 13, 1966, Ser. No. 520,328 4 Claims. (Cl. 22915) This invention relates toan improvement in bulk condiificulty has been experienced in preventing the Walls of the container from bulging outwardly. In some instances, manufacturers have gone so far as to: provide a rigid rectangular frame of aluminum or other such the event they are piled one uponthe otherf Another rigid materials encircling the walls of the container during storage and shipment to hold the walls from bulging.

In view of the fact that the tendency for the walls of containers of this type to bulge outwardly is directly related to the size of the 'walls, it is evident that bulge may be prevented by reducing the size of the containers. This, of course, is just what bulk packages aredesigned to eliminate. When small containers are used, each of the containers must be individually closed after it is filled. Furthermore, while a unit load comprising a series of relatively small containers may be piled on a pallet, some means must be provided for holding these smallercontainers together as a unit. Additionally, a series of small containers are usually much slower to fill than a single larger container.

An object of the present invention resides in the provision of a container which comprises a pair of body por tions in side-by-side relation. Each of the body portions comprises a generally rectangular sleeve of paperboard having a bottom closure cap closing the lower end of each sleeve. The two container bodies are preferably of the same dimensions. By placing the two containers in side-by-side relation upon apallet, the two container bodies may be filled substantially as easily and rapidly as a single open top container. After the container bodies have been filled, a single copy closure cap is applied over the tops of the two side-by-side container bodies. As a result, the structure can be closed as easily as a single open top container. At the same time, two opposed walls of the container bodies have an area of substantially one-half the area of the single container designed to contain the same weight of contents.

A further feature of the-present invention resides in the provision of a container comprising a pairof similar container bodies which are folded to provide rectangular recesses at each of the four outer corners of the containers when in side-by-side relation. Rectangular corner posts are provided in each of these four recesses, the corner posts being substantially the same height as the container bodies. The corner posts are held in place by the top and bottom caps. Theresulting container is capable of withstanding a very substantial compressive force. The outer corners of the container are strengthened by the corner posts, while the center portion of the container is greatly strengthened by the two inner opposed walls of the two bodies which form, in effect, a transverse partition extending across the container. At the same time, the structure is considerably less costly to produce than a single rectangular container having a double partition wall extending across the center thereof.

3,276,658 Patented Oct. 4, 1966 ice A further feature of the present invention resides in the location of the weight-supporting corner posts. The rectangular recesses at the outer corners of the combined container sections are formed by scorelines which are parallel to, and spaced on opposite sides of, the fold line which would normally define the corner of the container. The two sections of the walls between the corner fold and the parallel score lines are folded inwardly into right angular relation. This action in itself forms a corner which will sustain more compressive force than a corner without such a rectangular recess. By placing the rectangular corner posts in these rectangular recesses, the strength is much more greatly increased.

Providing rectangular recesses in the four corners of the container provides certain advantages which are not immediately obvious. The corner posts require no special means of attachment to the container as is the case when interior posts are used. Furthermore, the formation of rectangular recesses at the two outer corners of each container section reduces the width of three of the four container walls of each section. The width of these three walls is decreased by the width of the recesses, materially reducing the area against which the container contents may apply pressure. The only walls which are equal in size to the walls of a single container of similar size are the two inner opposed walls which bear against each other. A further feature of the present invention lies in the provision of a collapsible frame which is secured encircling the two container sections during the filling operation. This frame may hold the two sections in contact so that the container may be filled substantially as easily as a single container. The frame also holds the walls from bulging outwardly at their upper ends until the cover cap has been applied. Once the cover has been applied, the frame is removed.

These and other objects and novel features of the present invention will be more clearly and fully set forth in the following specification and claims.

In the drawings forming a part of the specification,

. FIGURE 1 is a perspective view of the bulk container after it has been filled but before the temporary wall supporting frame has been removed.

FIGURE 2 is a perspective view of the container with the top cap removed, portions of the container walls having been broken away to disclose the construction.

FIGURE 3 is a horizontal sectional view through one of the corners of the container, the position of the section being indicated by the line 3--3 of FIGURE 1.

FIGURE 4 is a diagrammatic view of the blank from which the top caps of the container are formed.

FIGURE 5 is a diagrammatic view showing the manner in which the blank forming the walls of the container are formed.

FIGURE 6 is a diagrammatic view of the blank from which the bottom caps are formed.

I FIGURE 7 is a diagrammatic view of the blank from which the corner posts are formed.

FIGURE 8 is a plan view of the temporary frame used to encircle the walls of the container during the filling operation.

The container-A is made of nine par-ts. Two of these parts comprise wall sections which are indicated in general by the letter B. A third part comprises a top cap which is indicated in general by the letter C. Two of the parts comprise identical bottom caps which are indicated in general by the letter D. Four corner posts are employed which are indicated in general by the letter B. In addition, a temporary frame is used for holding the walls frombulgingduring the filling operation, this frame being indicated in general by the letter F.

The side wall sections B include an inside wall panel hingedly connected along a fold line 11 to an end wall 12. The end wall 12 is foldably connected along a corner fold line 13 to an outer side wall 14. This outer side Wall 14 is connected along a fold 15 to a second end wall 15. The end wall 16 is foldably connected along a fold line 17 to a glue flap or stitch flap 19, which is designed to overlap the edge of the inner side wall 10, and is secured in face contact therewith to form a tubular body.

Rectangular recesses 20 are formed at the juncture between the outer side walls 14 and the end walls 12 and 16. Fold lines 21 and 22 extend vertically across the end wall 12 and the side wall 14, spaced on opposite sides of the corner fold line 13. In the structure illustrated, the fold lines 21 and 22 are equally spaced from the fold line 13 due to the fact that the corner posts E are shown as rectangular in cross section. The space between the corner fold line 13 and the fold line 21 forms a recess panel 23, while the space between the corner fold line 13 and the fold line 22 forms a second recess panel 24-.

In a similar manner, fold lines 25 and 26 extend vertically across the outer side wall 14 and the end wall 16 in parallel spaced relation to the corner fold line 15. The fold lines 25 and 26, together with the corner fold line 15, form recess panels 27 and 29 which are designed to form the Walls of the rectangular recess.

The top cap C includes a top panel 30 of rectangular form and of a size to overlie the upper ends of two wall sections B when the wall sections are in side-by-side relation. The top panel 30 is connected along parallel fold lines 33 to side flanges 34 which in turn are connected by spaced fold lines 35 to side wall liner flanges 36. Corner flaps 37 are foldably connected to the side edges of the flanges 32 along fold lines 39 which are substantially aligned with the fold lines 33. Corner flaps 40 are hingedly connected to the ends of the liner flanges 36 along fold lines 41 which are substantially aligned with the fold lines 31.

The bottom caps D are formed as best illustrated in FIGURE 6 of the drawings. Each bottom cap includes a rectangular bottom panel 42 hingedly connected along parallel fold lines 43 to end flanges 44. The remaining parallel edges of the bottom panel 42 are connected along parallel fold lines 45 to side wall flanges 46. The flanges 46 are connected by spaced parallel fold lines 47 to side wall liner flanges 49. The side edges of the end flanges 44 are connected along fold lines 50, which are substantially extensions of the fold lines 45, to corner flaps 51. The side wall liner flanges 49 are connected to corner flaps 52 along fold lines 53 which are substantially extensions of the fold lines 43.

The corner posts E comprise rectangular sheets of corrugated paperboard or similar material which are divided into four panels 54, 55, 56, and 57 by three parallel fold lines 58 which are parallel to the longitudinal edges 59 of the sheet. While the panels 54, 55, 56, and 57 are shown as being of equal width, the corner posts can be formed other than square with alternate panels being of equal width.

A temporary wall supporting frame F may be formed of strips of wood or metal capable of forming a rectangular frame dimensioned to encircle the walls of two side-by-side container sections and to hold their upper ends in contact. Two of the strips 60 and 61 may be rigidly connected in right angular relation at 62 although this connection can be pivotal if it is preferred. A third strip 63 is pivotally connected to an end of the strip 60 by a vertical pivot 64 while the fourth strip 65 is pivotally connected to the end of the strip 61 by vertical pivot 66. A removable pin 67 is designed for insertion through suitable apertures in the ends of the strips'63 and 65, to secure these strips in right angular relation. A flexible connector 69 may be anchored at one end to the strip 63 and at its other end to the strip 65 to limit the outward pivoting 0f the strips 63 and 65. The connecting cord 69 is merely provided as a matter of convenience, and to permit the frame to spread apart sufficiently so that it can be put into position encircling the Walls of a container and removed therefrom with a minimum of difliculty.

The wall structure B is connected into flat folded form by folding the blank along diagonally opposite corner fold lines such as 11 and 15 and attaching the stitch or glue flap 19 in face contact with an edge of the inner side wall 10.

The top cap is formed into its tray-like form by folding the end flanges 32 into right angular relation to the top panel 30 and folding the corner flaps 37 inwardly into right angular relation to the flanges 32 and to overlie the fold lines 33. The side wall flanges 34 are next folded upwardly and outwardly of the corner flaps 37 to extend in right angular relation to the top panel 30. The liner flanges 36 are then folded inwardly and downwardly over the corner flaps 37 to lock the corner flaps 37 in position. The corner flaps 40 engage inwardly of the end flanges 32, and fractionally hold the top cap assembled.

The two bottom caps D are erected into tray-shaped form in much the same manner as the top cap. The end flanges 44 are folded upwardly along the fold lines 43 and the corner flaps 51 are folded inwardly into right angular relation to the flanges 44 to generally overlie the fold lines 45. The side flanges 46 are then folded upwardly, outwardly of the corner flaps 51, and the liner flanges 49 are folded inwardly and downwardly to lock the corner flaps 51 in position. The corner flaps 52 engage the inner surface of the end flanges 44 to frictionally lock the liner flanges 49 in position parallel to the side wall flanges 46 to which they are connected.

The corner posts E are preferably taped into tubular form by folding the outer panels 54 and 57 into face contact with the inner panels 55 and 56, and securing the edges of the panels 54 and 57 by tape or other suitable means.

In assembling the container A, a wall section B is formed into tubular form, and the recess panels 23, 24, and 27, 29 are folded inwardly into right angular relation to the panels to which they are hinged. When in this position, the tubular wall unit is inserted into a bottom cap D which holds the wall sections folded in the manner described. After two such wall sections have been inserted in the end caps D, they are placed in side-by-side relation on a pallet with the inner side walls 10 in adjacent contiguous relation. A corner post E is inserted in each of the four rectangular recesses at the outer corners of the composite container. When thus arranged, the frame F is placed in position to encircle the two side-byside sections, as indicated in FIGURE 1 of the drawings.

If the containers are used for a bulk product such as meat or poultry, the narrow space between the panels 10 of the two containers caused by the side walls of the bottom caps D is of no importance. However, if the containers are to be used for .a flowable material, the distance between two spaced frame strips such as 61 and 63 is such that the upper portions of the panels 10 of the two sections are in face contact during the filling operation. This arrangement also simplifies the application of the top cap C.

After the top cap C has been applied, the temporary frame F is removed, and the container is ready for shipping or for storage. The corner posts, as well as the right angular recess forming panels against which the corner posts engage, greatly strengthen the outer corners of the container, and permit one container to be stacked upon another. The side wall panels 10 act to provide a double thickness partition wall across the center of the composite container, thus further increasing the stacking strength.

Due to the construction in which the corner posts are located outside the container walls and are located in rectangular recesses at the outer corners of the container,

the effective width of the outer Wall panels against which the weight of the contents may act is materially decreased. If the corner posts were positioned within the container at the corners thereof, the width of the side wall panels 14 would extend from the corner fold 13 to the corner fold 15 or be of the width X illustrated in FIGURE 5. Due to the formation of the rectangular recesses, the width of the wall panels 14 is decreased to the distance between the fold lines 22 and 25, which is indicated in FIGURE 5 by the letter W.

In a similar manner, if the corner posts were located within the walls of the container, the width of the end walls such as 12 would be the distance between the corner folds 11 and 13. By forming the rectangular recesses at the outer container corners, the width of the end walls is decreased to the distance between the fold lines 11 and 21. Thus the tendency of these walls to bulge is materially reduced.

As a result of this arrangement, the only wall panels of the container which are of the same area as they would be in a conventional single container for the same product are the walls 10. However, the walls 10 are spaced apart a maximum distance equal to the thickness of the side flange structures of the bottom caps B. Accordingly, any bulging of the side walls 10 is limited to the distance between these side walls, and the bulging of these inner walls does not materially change the outer shape of the container.

In accordance with the patent statutes, I have described the principles of construction and operation of my improvement in bulk containers; while I have endeavored to set forth the best embodiment thereof, I desire to have it understood that obvious changes may be made within the the scope of the following claims without departing from the spirit of my invention.

I claim:

1. A bulk container for use in containing heavy products which tend to bulge the container walls, the container including;

a pair of substantially rectangular tubular wall structures having connected side and end walls and open top and bottom ends, the walls being connected along corner creases,

a pair of bottom caps including a bottom panel extending across the bottoms of said wall structures and in- 6 cluding upstanding rectangularly arranged side and end walls encircling the lower ends of said wall structures in telescoping relation thereto, and

said tubular wall structures being in side-by-side relation,

a single top cap including a top panel overlying the upper ends of both wall structures and including connected side and end Walls depending from the marginal edges of said top panel and encircling the periphery of the two side-by-side wall structures in telescoping relation thereto.

2. The structure of claim 1 and in which each said tubular wall structure is creased adjacent the corners joining one side wall to the two end walls along lines parallel to, and spaced from, the corner creases, and the portions of the walls between said corner creases and the space-d creases being folded inwardly to provide rectangular recesses at these corners, the other side walls of said wall structures being in closely spaced relation, and rectangular corner posts of a height substantially equal to the height of said tubular wall structure and substantially filling said recesses.

3. The structure of claim 2 and including a removable rigid frame encircling said si'de-by-side wall structures to facilitate application and removal of said top cap.

4. The structure of claim 1 and in which two opposed of said walls connected to said walls connected to said bottom panel include wall liner panels folded inwardly of said two opposed walls and the remaining two opposed walls include corner flaps lying between said two opposed walls and said liner panels.

References Cited by the Examiner UNITED STATES PATENTS 2,350,932 6/1944 Schaefer 229-32 2,694,518 11/1954 Zanck et al. 22915 2,734,676 2/1956 Lawrence 22923 2,968,397 1/ 1961 Cantrell 206- 3,066,842 12/1962 Croley 2297 3,087,666 4/1963 Kitchell 22915 3,185,379 5/ 1965 Kohlhaas 22923 GEORGE O. RALSTON, Primary Examiner. 

1. A BULK CONTAINER FOR USE IN CONTAINING HEAVY PRODUCTS WHICH TEND TO BULGE THE CONTAINER WALLS, THE CONTAINER INCLUDING; A PAIR OF SUBSTANTIALLY RECTANGULAR TUBULAR WALL STRUCTTURES HAVING CONNECTED SIDE AND END WALLS AND OPEN TOP AND BOTTOM ENDS, THE WALLS BEING CONNECTED ALONG CORNER CREASES, A PAIR OF BOTTOM CAPS INCLUDING A BOTTOM PANEL EXTENDING ACROSS THE BOTTOMS OF SAID WALL STRUCTURES AND INCLUDING UPSTANDING RECTANGULAR ARRANGED SIDE AND END WALLS ENCIRCLING THE LOWER ENDS OF SAID WALL STRUCTURES IN TELESCOPING RELATION THERETO, AND SAID TUBULAR WALL STRUCTURES BEING IN SIDE-BY-SIDE RELATION, A SINGLE TOP CAP INCLUDING A TOP PANEL OVERLYING THE UPPER ENDS OF BOTH WALL STRUCTURES AND INCLUDING CONNECTED SIDE AND END WALLS DEPENDING FROM THE MARGINAL EDGES OF SAID TOP PANEL AND ENCIRCLING THE PERIPHERY OF THE TWO SIDE-BY-SIDE WALL STRUCTURES IN TELESCOPING RELATION THERETO. 